U.S. patent application number 13/874748 was filed with the patent office on 2014-11-06 for configurable linear light assembly and associated methods.
This patent application is currently assigned to LIGHTING SCIENCE GROUP CORPORATION. The applicant listed for this patent is LIGHTING SCIENCE GROUP CORPORATION. Invention is credited to David E. Bartine, Fredric S. Maxik, Mark Andrew Oostdyk, Robert R. Soler, Addy S. Widjaja.
Application Number | 20140328055 13/874748 |
Document ID | / |
Family ID | 51841338 |
Filed Date | 2014-11-06 |
United States Patent
Application |
20140328055 |
Kind Code |
A1 |
Maxik; Fredric S. ; et
al. |
November 6, 2014 |
CONFIGURABLE LINEAR LIGHT ASSEMBLY AND ASSOCIATED METHODS
Abstract
A linear light assembly having an elongate tray and a plurality
of moveable lighting packages. The elongate tray may provide both
mechanical support and thermal management for the plurality of
moveable lighting packages. The elongate tray may comprise a medial
channel portion with a planar track member and two opposing rim
members projecting perpendicularly outward therefrom. Each flange
portion may have a U-shaped cross-section. Each moveable package
may comprise an assembly tray and an optical assembly having at
least one light-emitting device (LED). Each moveable lighting
package may be adjustably positioned along and independently
removed from the front side of the track member of the elongate
tray. Any segmentation of the elongate tray may be characterized by
a heat dissipation rate not less than a combined heat generation
rate of all moveable lighting packages carried by the segment. A
method aspect includes installation of the linear light
assembly.
Inventors: |
Maxik; Fredric S.;
(Indialantic, FL) ; Widjaja; Addy S.; (Palm Bay,
FL) ; Oostdyk; Mark Andrew; (Cape Canaveral, FL)
; Soler; Robert R.; (Cocoa Beach, FL) ; Bartine;
David E.; (Cocoa, FL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
LIGHTING SCIENCE GROUP CORPORATION |
Satellite Beach |
FL |
US |
|
|
Assignee: |
LIGHTING SCIENCE GROUP
CORPORATION
Satellite Beach
FL
|
Family ID: |
51841338 |
Appl. No.: |
13/874748 |
Filed: |
May 1, 2013 |
Current U.S.
Class: |
362/218 ;
29/592.1 |
Current CPC
Class: |
F21V 29/767 20150115;
F21V 19/0045 20130101; F21Y 2103/10 20160801; F21S 8/03 20130101;
Y10T 29/49002 20150115; F21Y 2115/10 20160801; F21S 4/28 20160101;
F21Y 2113/00 20130101 |
Class at
Publication: |
362/218 ;
29/592.1 |
International
Class: |
F21V 21/005 20060101
F21V021/005; F21V 29/00 20060101 F21V029/00 |
Claims
1. A linear light assembly comprising: an elongate tray comprising
a medial channel portion comprising a track member having a
substantially planar main body defining, on opposite sides thereof,
generally flat front and rear sides, and defining, on a perimeter
thereof, upper and lower edges, and two opposing rim members
adjacent to the upper and lower edges of the track member,
respectively; and first and second flange portions each comprising
a base member and a plurality of fin members adjacent to the base
member; and a plurality of moveable lighting packages carried by
and in thermal communication with the elongate tray, and each
comprising an assembly tray, and an optical assembly carried by the
assembly tray and comprising at least one light source.
2. A linear light assembly according to claim 1 wherein each rim
member is longitudinally coextensive with the track member.
3. A linear light assembly according to claim 1 wherein each rim
member is configured to project outward in a generally
perpendicular direction with respect to the front side of the track
member.
4. A linear light assembly according to claim 1 wherein each of the
first and second flange portions is longitudinally coextensive with
the track member.
5. A linear light assembly according to claim 1 wherein at least
one of the first and second flange portions has a substantially
U-shaped cross-section formed by the base member and the plurality
of fin members; wherein the base member of the U-shaped
cross-section has a substantially planar central body defining, on
opposite sides thereof, generally flat first and second sides, and
defining, on a perimeter thereof, generally linear leading and
trailing edges; wherein the plurality of fin members of the
U-shaped cross-section comprises two opposing fin members
positioned adjacent to the leading and trailing edges of the base
member, respectively, and each fin member is configured to project
perpendicularly outward from the base member in a generally
parallel direction with respect to the substantially planar main
body of the track member.
6. A linear light assembly according to claim 5 wherein the second
side of the base member of the U-shaped cross-section is attached
to a respective rim member of the medial channel portion.
7. A linear light assembly according to claim 1 wherein the
elongate tray is configured to have a plurality of mounting
positions; wherein each of the plurality of mounting positions is
suitable for mounting one of the plurality of moveable lighting
packages so that each of the plurality of moveable lighting
packages can be moveably positioned along the front side of the
elongate track member.
8. A linear light assembly according to claim 1 wherein each of the
plurality of moveable lighting packages is configured for removal
from the front side of the track member independently of each
other.
9. A linear light assembly according to claim 1 wherein the
elongate tray comprises a plurality of tray segments each in
mechanical and thermal communication with a subset of the plurality
of moveable lighting packages; wherein a heat dissipation rate of
each of the plurality of tray segments is not less than a combined
heat generation rate of the subset of the plurality of moveable
lighting packages.
10. A linear light assembly according to claim 1 wherein the
elongate tray comprises at least one mounting assembly configured
to receive a respective at least one of the plurality of moveable
lighting packages; and wherein the at least one mounting assembly
is of a type selected from the group consisting of fasteners,
snap-fit connectors, and fitted grooves.
11. A linear light assembly according to claim 1 wherein the medial
channel portion and the first and second flange portions are
integrally molded as a monolithic unit; and wherein the optical
assembly and the assembly tray are integrally molded as a
monolithic unit.
12. A linear light assembly according to claim 1 wherein the
elongate tray is configured to connect mechanically and thermally
to a housing; and wherein a combined heat dissipation rate of the
elongate tray and of the housing is not less than a combined heat
generation rate of the plurality of moveable lighting packages in
thermal communication with the elongate tray.
13. A linear light assembly according to claim 1 wherein the
elongate tray is constructed of a heat-dissipating material
selected from the group consisting of thermoplastic, ceramic,
porcelain, aluminum, and aluminum alloys.
14. A linear light assembly according to claim 1 wherein the
assembly tray and the track member form a generally central
passageway therebetween configured to allow an electrical
connection to pass from a power supply through an aperture in the
track member and to extend through the central passageway to an
electrical contact on the at least one light source.
15. A linear light assembly comprising: an elongate tray configured
to have a plurality of mounting positions and comprising a medial
channel portion comprising a track member having a substantially
planar main body defining, on opposite sides thereof, generally
flat front and rear sides, and defining, on a perimeter thereof,
upper and lower edges, and two opposing rim members adjacent to the
upper and lower edges of the track member, respectively, wherein
each rim member is longitudinally coextensive with the track
member; and first and second flange portions each having a base
member and a plurality of fin members adjacent to the base member
so as to form a substantially U-shaped cross section, each of the
first and second flange portions being longitudinally coextensive
with the track member, a plurality of moveable lighting packages
carried by and in thermal communication with the elongate tray, and
each comprising an assembly tray, and an optical assembly carried
by the assembly tray and comprising at least one light emitting
diode (LED); wherein each of the plurality of mounting positions on
the elongate tray is suitable for mounting one of the plurality of
moveable lighting packages so that each of the plurality of
moveable lighting packages can be moveably positioned along the
front side of the elongate track member.
16. A linear light assembly according to claim 15 wherein the
elongate tray is constructed of a heat-dissipating material
selected from the group consisting of thermoplastic, ceramic,
porcelain, aluminum, and aluminum alloys.
17. A linear light assembly according to claim 15 wherein the
elongate tray comprises a plurality of tray segments each in
mechanical and thermal communication with a subset of the plurality
of moveable lighting packages; wherein a heat dissipation rate of
each of the plurality of tray segments is not less than a combined
heat generation rate of the subset of the plurality of moveable
lighting packages.
18. A method of installing a linear light assembly comprising an
elongate tray in mechanical and thermal communication with each of
a plurality of moveable lighting packages, the elongate tray
characterized by a plurality of mounting positions suitable for
mounting of one of the plurality of moveable lighting packages, and
comprising a medial channel portion comprising a track member
having a substantially planar main body defining on opposite sides
thereof generally flat front and rear sides and defining on a
perimeter thereof upper and lower edges, and two opposing rim
members adjacent to the upper and lower edges of the track member,
respectively; and first and second flange portions each comprising
a base member and a plurality of fin members adjacent to the base
member; and each of the plurality of moveable lighting packages
comprising an assembly tray and an optical assembly carried by the
assembly tray and comprising at least one light source; the method
comprising: adjustably positioning each of the moveable lighting
packages on the medial channel portion of the elongate tray;
affixing the each of the plurality of moveable lighting packages to
a respective mounting position.
19. A method according to claim 18 wherein the elongate tray
further comprises first and second tray segments; the method
further comprising: moving each of a first subset of the plurality
of moveable lighting packages to a respective mounting position on
the first tray segment; removing each of a second subset of the
plurality of moveable lighting packages from the second tray
segment; mechanically separating the second tray segment and the
first tray segment; mounting the first tray segment to a light
fixture.
20. A method according to claim 19 wherein mechanically separating
the second tray segment and the first tray segment comprises
cutting the elongate tray; and further comprising removing the
power supply from the second tray segment and mounting the power
supply to the first tray segment.
Description
RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application Ser. No. 61/643,310 filed on May 6, 2012 and
titled Configurable Linear Light and Associated Methods, the entire
contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of illumination
devices and, more specifically, to the field of light-emitting
diode (LED)-based linear illumination devices, and associated
methods.
BACKGROUND OF THE INVENTION
[0003] Linear-type illumination devices typically are characterized
by multiple light sources mounted and spaced apart from one another
along a length of an elongate substrate. Such illumination devices
are often designed to present a low profile when installed flush to
an existing surface, such as a wall.
[0004] Current linear illumination device designs commonly consist
of multiple members that often are complex to manufacture and
assemble. For example, linear illumination device components may
include light sources, circuit boards, power supplies, heat sinks,
support structures, electrical connectors, external housings,
enclosures/reflectors, and inter-member fasteners. Design
complexity may negatively impact both the manufacturability and the
ease of installation of linear illumination devices.
[0005] More specifically, design complexity may complicate volume
manufacturing of illumination products, which often involves
collaboration between Original Equipment Manufacturers (OEMs) and
Value Added Resellers (VARs). As used herein, an OEM is a company
whose capital goods are used as components in other companies'
finished consumer goods. A VAR is a company that builds and sells a
finished consumer good using an OEM's components. The OEM often
will customize component designs based on a VAR's requirements.
Complexity of design in a component and/or a finished consumer good
often results in error-prone and time-consuming assembly processes,
and may make separation of distinct product manufacturing
responsibilities among OEMs and VARs unworkably difficult.
[0006] A major design decision that may significantly impact
illumination product cost and complexity is selection of the type
of light sources to include in the product. For example, digital
lighting technologies such as light-emitting diodes (LEDs) offer
significant advantages over legacy light sources such as
incandescent and fluorescent lamps. These advantages include, but
are not limited to, better lighting quality, longer operating life,
and lower energy consumption. Consequently, LED-based lamps
increasingly are being used not only in original product designs,
but also in products designed to replace legacy light sources in
conventional lighting applications such as linear lighting devices.
However, a number of design challenges and costs are associated
with replacing traditional lamps with LED illumination devices.
These design challenges include thermal management, installation
ease, and manufacturing cost control.
[0007] The complex designs of current LED-based linear illumination
devices often suffer from high material and component costs, and
also from cumbersome component configurations that may sacrifice
lighting adjustability and limit customization options. Design
decisions that fix the positions or interrelationships between
members of a linear illumination device can compromise the ability
of a manufacturer and/or an installer to tailor or reconfigure the
device to meet a consumer's lighting performance requirements.
[0008] The lighting industry is experiencing advancements in LED
applications, some of which may be pertinent to improving the
design of linear illumination devices.
[0009] U.S. Pat. No. 7,815,341 to Steedy et al. discloses a
low-profile strip illumination device having a substrate supporting
an elongate heat conductor as well as positively and negatively
charged elongate rails. A plurality of LEDs are mounted so as to be
powered by the elongate rails, and so as to define a heat flow path
from each LED through the elongate heat conductor and to the
environment. However, relying on separate components for mechanical
support (i.e., the substrate) and for thermal management (i.e., the
elongate heat conductor) adds to design complexity for the
disclosed device.
[0010] U.S. Pat. No. 8,267,540 to Klus discloses a linear lighting
apparatus that includes an elongated element having a substantially
U-shaped cross section and an LED strip placed longitudinally along
a bottom of the elongated element. However, the depth of the
U-shape elongated element presumes recessed mounting, thereby
precluding low-profile flush-mounting applications. Also, the
placement of LEDs on a common strip prevents reconfiguration and/or
replacement of subsets of the LEDs employed in the linear lighting
apparatus.
[0011] U.S. patent application Ser. No. 11/026,816 by Reo et al.
discloses a linear lighting apparatus having a plurality of LEDs, a
plurality of optical assemblies, and a housing. The apparatus
housing is configured to hold a secondary optical assembly and to
dissipate radiated energy from the LEDs. However, the depth of the
U-shaped housing suffers the same recessed mounting disadvantage as
the Klus implementation. Furthermore, delegating primary mechanical
support of the optical assemblies to an LED tray while relying on
the housing to provide primary thermal management for the optical
assemblies results in a component proliferation problem similar to
that exhibited by the Steedy implementation.
[0012] Accordingly, a need exists for a low-profile, LED-based
linear illumination device that is less complex in design, less
expensive to manufacture and assemble, reconfigurable during
assembly and post-installation, and efficient at heat
dissipation.
[0013] This background information is provided to reveal
information believed by the applicant to be of possible relevance
to the present invention. No admission is necessarily intended, nor
should be construed, that any of the preceding information
constitutes prior art against the present invention.
SUMMARY OF THE INVENTION
[0014] With the foregoing in mind, embodiments of the present
invention are related to a linear light assembly used to produce a
configurable beam of light emanating along a length of a luminaire.
Embodiments of the present invention advantageously may provide an
LED-based linear illumination device that is less complex in
design, is less expensive to manufacture, is reconfigurable during
assembly and post-installation, and is efficient with respect to
heat dissipation.
[0015] These and other benefits, features and advantages are
preferably provided by a linear light assembly according to
embodiments of the present invention that may include an elongate
tray and a plurality of moveable lighting packages. The
single-member, dual-purpose elongate tray may be configured to be
employed advantageously to provide both mechanical support and heat
dissipation during the operation of the moveable lighting packages.
Each of the moveable lighting packages may be reconfigured during
assembly and post-installation to advantageously adjust the
direction of light emitted by at least one light source.
Modularization of other components designed to mount to the
elongate tray, including power supplies and custom finishes, may
advantageously facilitate collaborative manufacturing of
linear-type illumination devices among participating OEMs and VARs.
More specifically, modularization may equip an OEM to efficiently
and inexpensively produce a universal linear fixture, deliverable
in various states of completeness of assembly and staged for
finishing by several different VARs. VARs, in turn, may use
universal linear fixtures produced by OEMs to tailor finished
linear-type illumination devices for consumption by diverse
customers.
[0016] The elongate tray may comprise a medial channel portion, and
first and second flange portions. The medial channel portion may
comprise a track member and two opposing rim members. The track
member may have a substantially planar main body with generally
flat front and rear sides and with upper and lower edges. The two
opposing rim members may be positioned adjacent to the upper and
lower edges of the track member. Each rim member may be
longitudinally coextensive with the track member, and may be
configured to project outward in a generally perpendicular
direction with respect to the front side of the track member. The
medial channel portion and the first and second flange portions may
be integrally molded as a monolithic unit.
[0017] Each of the first and second flange portions may have a
substantially U-shaped cross-section defined by a base member and
fin members. The base member may comprise a substantially planar
central body with generally flat first and second sides and with
generally linear leading and trailing edges. The two opposing fin
members may be positioned adjacent to the leading and trailing
edges of the base member, respectively, and may be configured to
project perpendicularly outward from the base member in a generally
parallel direction with respect to the main body of the track
member. The second sides of the base members of the first and
second flange portions each may be attached to a respective rim
member of the medial channel portion. Each of the first and second
flange portions may be longitudinally coextensive with the track
member.
[0018] Each of the plurality of moveable lighting packages may
comprise an assembly tray and an optical assembly. The optical
assembly may comprise at least one light source, and may be carried
by the assembly tray. The optical assembly and the assembly tray
may be integrally molded as a monolithic unit. A power supply may
be in electrical communication with each light source. A generally
central passageway may be formed between the assembly tray and the
medial channel portion. An electrical connection may pass from the
power supply through an aperture in the track member, and may
extend through the central passageway to an electrical contact on
each light source. Each light source may comprise a light emitting
diode (LED).
[0019] The elongate tray may come into mechanical communication
with each of the moveable lighting packages. More specifically, the
elongate tray may further comprise a plurality of tray segments
each in mechanical communication with a subset of the moveable
lighting packages. Each of the moveable lighting packages may be
moveably positioned along and independently removed from the front
side of the track member. The elongate tray may include at least
one mounting assembly, each of which may comprise fasteners,
snap-fit connectors, and/or fitted grooves. The elongate tray may
include mounting positions each suitable for mounting one of the
moveable lighting packages to a mounting assembly. The elongate
tray may be configured to mechanically connect to a housing and/or
to a fixture.
[0020] The elongate tray may be positioned in thermal communication
with each of the moveable lighting packages. The elongate tray may
be characterized by a heat dissipation rate of not less than a
combined heat generation rate of the moveable lighting packages.
More specifically, the elongate tray may comprise a plurality of
tray segments each in thermal communication with a subset of the
moveable lighting packages. Each of the tray segments may have a
heat dissipation rate of not less than a combined heat generation
rate of the subset of the moveable lighting packages with which the
try segment makes contact. The elongate tray may be constructed of
a heat-dissipating material such as thermoplastic, ceramic,
porcelain, aluminum, and aluminum alloys. The elongate tray may be
configured to connect thermally to the housing such that a combined
heat dissipation rate of the elongate tray and of the housing is
not less than a combined heat generation rate of the packages.
[0021] A method aspect according to an embodiment of the present
invention is for installing a linear light assembly. The method may
comprise adjustably positioning each of the moveable lighting
packages on the medial channel portion of the elongate tray, and
affixing each of the moveable lighting packages to a respective
mounting position. The installation method may further comprise
moving a first subset of the moveable lighting packages to a
respective mounting position on a first tray segment, removing a
second subset of the moveable lighting packages from a second tray
segment, separating the second tray segment from the first tray
segment, and mounting the first tray segment to a light fixture.
The installation method may still further comprise removing the
power supply from the second tray segment, and mounting the power
supply to the first tray segment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a perspective view of a linear light assembly
according to an embodiment of the present invention.
[0023] FIG. 2 is an exploded perspective view of the linear light
assembly illustrated in FIG. 1.
[0024] FIG. 3 is a front elevation view of the linear light
assembly illustrated in FIG. 1.
[0025] FIG. 4 is a right side elevation view of the linear light
assembly illustrated in FIG. 1.
[0026] FIG. 5 is a left side elevation view of the linear light
assembly illustrated in FIG. 1.
[0027] FIG. 6 is a top plan view of the linear light assembly
illustrated in FIG. 1.
[0028] FIG. 7 is a rear elevation view of an elongate LED tray of
the linear light assembly illustrated in FIG. 1.
[0029] FIG. 8 is a perspective view of the linear light assembly
illustrated in FIG. 1, and showing the linear light assembly
connected to an optional housing and to an optional fixture.
[0030] FIG. 9 is an exploded perspective view of the linear light
assembly and optional housing and optional fixture illustrated in
FIG. 8.
[0031] FIG. 10 is a flow chart detailing a method of manufacturing
a linear light assembly according to an embodiment of the present
invention.
[0032] FIG. 11 is a flow chart detailing a method of installing a
linear light assembly according to an embodiment of the present
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0033] The present invention will now be described fully
hereinafter with reference to the accompanying drawings, in which
preferred embodiments of the invention are shown. This invention
may, however, be embodied in many different forms and should not be
construed as limited to the embodiments set forth herein. Rather,
these embodiments are provided so that this disclosure will be
thorough and complete, and will fully convey the scope of the
invention to those skilled in the art. Those of ordinary skill in
the art will realize that the following embodiments of the present
invention are only illustrative and are not intended to be limiting
in any way. Other embodiments of the present invention will readily
suggest themselves to such skilled persons having the benefit of
this disclosure.
[0034] Although the following detailed description contains many
specifics for the purposes of illustration, anyone of ordinary
skill in the art will appreciate that many variations and
alterations to the following details are within the scope of the
invention. Accordingly, the following embodiments of the invention
are set forth without any loss of generality to, and without
imposing limitations upon, the claimed invention.
[0035] In this detailed description of the present invention, a
person skilled in the art should note that directional terms, such
as "above," "below," "upper," "lower," "front," "rear," and other
like terms are used for the convenience of the reader in reference
to the drawings. Also, a person skilled in the art should notice
this description may contain other terminology to convey position,
orientation, and direction without departing from the principles of
the present invention. Like numbers refer to like elements
throughout.
[0036] Referring now to FIGS. 1-10, a linear light assembly 100
used to produce a configurable beam of light emanating along a
length of a luminaire, according to an embodiment of the present
invention, is now described in detail. Throughout this disclosure,
the present invention may be referred to as a configurable linear
light assembly 100, a strip illumination device, a light strip, a
linear light, a lamp system, a lamp, a device, a system, a product,
or a method. Those skilled in the art will appreciate that this
terminology is only illustrative and does not affect the scope of
the invention.
[0037] Example systems and methods for a configurable linear light
assembly are described herein below. In the following description,
for purposes of explanation, numerous specific details are set
forth to provide a thorough understanding of example embodiments.
It will be evident, however, to one of ordinary skill in the art
that the present invention may be practiced without these specific
details and/or with different combinations of the details than are
given here. Thus, specific embodiments are given for the purpose of
simplified explanation and not limitation.
[0038] Referring now to FIG. 1, a configurable linear light
assembly 100 will now be discussed. The linear light assembly 100,
according to an embodiment of the present invention, may include an
elongate tray 110 and a plurality of moveable lighting packages
120. For example, and without limitation, the configurable linear
light assembly 100 may advantageously be used as a low profile
linear accent luminaire, suitable for indoor and/or outdoor
applications. In addition, the linear light assembly 100 may
advantageously be customizable in length.
[0039] Each of the moveable lighting packages 120 may be mounted
upon the elongate tray 110. Although the configuration of the
linear light assembly illustrated in FIG. 1 shows four moveable
lighting packages 120 approximately equally spaced apart, the
skilled artisan will appreciate that moveable lighting packages 120
may be positioned anywhere along the elongate tray 110 prior to
being fastened thereto. The skilled artisan will further appreciate
that any number of light packages 120 may be provided along the
elongate tray 110, while still accomplishing the goals, features
and objectives of the linear light assembly 100 according to an
embodiment of the present invention. This spacing feature
advantageously may enhance the flexibility of use of the linear
light assembly 100. The components comprising the light assembly
100 may be connected by any means known in the art, including, not
by limitation, use of adhesives or glues, welding, interference
fit, and fasteners. Alternatively, one or more components of the
light assembly 100 may be molded during manufacturing as an
integral part of the light assembly 100.
Elongate Tray Configuration
[0040] Referring now to FIG. 2, the elongate tray 110 of the light
assembly 100 according to an embodiment of the present invention is
now discussed in greater detail. For example, and without
limitation, the elongate tray 110 may comprise a medial channel
portion 212, and first and second flange portions 222.
[0041] Continuing to refer to FIG. 2, and referring additionally to
FIGS. 3, 4 and 5, the medial channel portion 212 may comprise a
track member 314 and two opposing rim members 316. For example, and
without limitation, the track member 314 may have a substantially
planar main body with generally flat front 218 and rear sides and
with upper and lower edges. Those skilled in the art will
appreciate that a substantially planar main body is intended to
note that the main body may have a shape that is planar. Those
skilled in the art will also appreciate that shapes of the main
body that are not precisely planar are meant to be included within
the scope and spirit of the embodiments of the present invention.
The two opposing rim members 316 may be positioned adjacent to the
upper and lower edges of the track member 314. Each rim member 316
may be longitudinally coextensive with the track member 314, and
may be configured to project outward in a generally perpendicular
direction with respect to the front side 218 of the track member
314.
[0042] Continuing to refer to FIGS. 2, 4 and 5, each of the first
and second flange portions 222 may have a substantially U-shaped
cross-section defined by a base member 424 and two opposing fin
members 426. Those skilled in the art will appreciate that use of
the term "substantially" when describing the U-shaped cross section
of the flange portions 222 is meant to be inclusive of shapes that
are similar to a U-shaped shape, i.e., shapes that include a base
member 424 and opposing fin members 426. It is to be understood
that the opposing fin members 426 are contemplated to extend from
the base member at any angle suitable for forming a U-shape. For
example, the present invention contemplates that the fin members
426 may extend from the base member 424 at any angle between about
75 degrees and 105 degrees. Those skilled in the art will
appreciate that these angles of extension of the fin members 426
from the base member 424 are exemplary in nature and not meant to
be limiting in any way. The base member 424 may comprise a
substantially planar central body with generally flat first and
second sides and with generally linear leading and trailing edges.
Those skilled in the art will appreciate that embodiments of the
present invention also contemplate fins and second sides that are
not precisely flat. The two opposing fin members 426 may be
positioned adjacent to the leading and trailing edges of the base
member 424, respectively, and may be configured to project
perpendicularly outward from the base member 424 in a generally
parallel direction with respect to the main body of the track
member 314. The second sides of the base members 424 of the first
and second flange portions 222 each may be attached to a respective
rim member 316 of the medial channel portion 212. Each of the first
and second flange portions 222 may be longitudinally coextensive
with the track member 314.
[0043] For example, and without limitation, the medial channel
portion 212 and the first and second flange portions 222 may be
integrally molded as a monolithic unit. Also for example, and
without limitation, the elongate tray 110 may have a maximum
overall depth of 1 inch, measured as the distance between the
leading and trailing edges of the widest of the base members 424 of
the two flange portions 222. Also for example, and without
limitation, the elongate tray 110 may have a maximum overall height
of 5 inches, measured as the distance between outermost points on
the fin members 426 of the first and second flange portions
222.
Moveable Lighting Package Configuration
[0044] Referring again to FIG. 2, the plurality of moveable
lighting packages 120 of the light assembly 100 according to an
embodiment of the present invention is now discussed in greater
detail. Each moveable lighting package 120 may operate as a
self-contained light-producing unit, and may comprise an assembly
tray 123 and an optical assembly 125.
[0045] Referring additionally to FIGS. 4 and 5, the optical
assembly 125 may comprise an optic 442 and at least one heat
generating element 444. For example, and without limitation, the
heat generating element 444 may be in the form of a light source
that may include any device capable of emitting light. The light
source may comprise one or more light emitting elements that may,
for example and without limitation, include light-emitting
semiconductors, such as light-emitting diodes (LEDs), lasers,
incandescent, halogens, arc-lighting devices, fluorescents, and any
other digital light-emitting device known in the art. In some
embodiments of the present invention, the light source may include
one or more LEDs 444 and a circuit board (not shown). The circuit
board may be configured to be functionally and/or mechanically
coupled to the LEDs 444.
[0046] LEDs normally produce singular points of light. However, the
linear light assembly 100 according to an embodiment of the present
invention may be configured to refract light produced from one or
more LEDs 444 in such a way as to produce a continuous linear beam
of light emanating along a length of the linear light assembly 100.
Such a beam of light may be useful, for example, in building
grazing applications or wall washing lighting effects. The optic
442 that may be included in the optical assembly 125 may be
configured to interact with light emitted by the LEDs 444 to
refract incident light. Accordingly, the LEDs 444 may be disposed
such that light emitted therefrom is incident upon the optic 442.
The optic 442 may be formed in any shape to impart a desired
refraction. For example, and without limitation, the optic 442 may
have a generally concave geometry. Additionally, the optic 442 may
be configured to generally diffuse light incident thereupon, and
from a material that refracts or collimates light emitted by the
LEDs 444.
[0047] The optic 442 may be formed of any material with transparent
or translucent properties that comport with the desired refraction
to be performed by the optic 442. For example, the optic 442 may
include an extruded refractory material. Alternatively, or in
addition, an exemplary material for the optic 442 may be an acrylic
material, such as cast acrylic or extruded acrylic. In addition,
the optic 442 may be formed of cast acrylic with diamond polishing.
Acrylic materials may be suitable for the optic 442 due to their
excellent light transmission and UV light stability properties.
[0048] Continuing to refer to FIGS. 2, 4 and 5, an external power
source used to power the linear light assembly 100 according to an
embodiment of the present invention is discussed in greater detail.
For example, and without limitation, a power supply 230 may be
mounted on the rear side 221 of the track member 314 and may be
configured to be in electrical communication with one or more light
sources 444 in the optical assembly 125. A generally central
passageway 437 may be formed between the assembly tray 123 and the
front side 218 of the track member 314 in the medial channel
portion 212. Referring additionally to FIG. 3, an electrical
connection may pass from the power supply 230 through an aperture
340 in the medial channel portion 212, and may extend through the
central passageway 437 to an electrical contact on a light source
444, such as an LED.
[0049] For example, and without limitation, the power source 230
may be in the form of an on-board power supply unit configured to
deliver electrical power to LEDs 444 present in the moveable
lighting packages 120. The on-board power supply unit 230 may have
a converter (not shown) that may convert an AC input voltage to a
DC output voltage. The on-board power supply unit 230 also may have
a regulator (not shown) that may sustain a DC output voltage within
a target DC bias range.
[0050] In one embodiment, the on-board power supply unit 230 may
have at least one induction coil (not shown) configured to receive
an AC input voltage through inductive coupling. In another
embodiment, the on-board power supply unit 230 may have at least
one wire connector configured to receive the AC input voltage
through conductive coupling. Alternatively, the power source 230
may be in the form of at least one power terminal (not shown) that
receives power from a source external to the linear light assembly
100, and that transmits that electrical power to the light sources
444 and/or other electronic components comprising the moveable
lighting packages 120. Additional information directed to the use
of power sources to deliver electric current to an illumination
apparatus is found in U.S. patent application Ser. No. 13/608,999
titled System for Inductively Powering an Electrical Device and
Associated Methods, the entire contents of which are incorporated
herein by reference.
Mechanical Communication
[0051] Referring again to FIGS. 2 and 3, the mechanism by which the
elongate tray 110 may come into mechanical communication with each
of the plurality of moveable lighting packages 120 of the light
assembly 100 according to an embodiment of the present invention is
now discussed in greater detail. A person skilled in the art will
appreciate that any manner of mounting a moveable lighting package
120 on the elongate tray 110 may be used.
[0052] The optical assembly 125 of each LED package 120 may be
carried by the assembly tray 123. A person skilled in the art will
appreciate that each assembly tray 123 may be bonded to an optical
assembly 125 using any manner of bonding. For example, and without
limitation, the optical assembly 125 and the assembly tray 123 may
be integrally molded as a monolithic unit.
[0053] Each of the plurality of moveable lighting packages 120 may
be configured to be both moveably positioned along and
independently removed from the front side 218 of the track member
314. For example, and without limitation, each assembly tray 123
may include a snap-fit connection to the recessed track member 314
of the elongate tray 110. In another example, each assembly tray
123 may be slid onto the recessed portion 218 of the track member
314 from one end of the elongate tray 110.
[0054] Referring additionally to FIGS. 6 and 7, the elongate tray
110 may further comprise a plurality of tray segments 610 each in
mechanical communication with a subset of the plurality of moveable
lighting packages 120. The elongate tray 110 may comprise at least
one mounting assembly each configured to receive a respective
moveable lighting package 120. For example, and without limitation,
the mounting assembly may comprise fasteners, such as one or more
screws 352 each positionable through a respective screw hole in one
of the assembly trays 123 and configured to mate with a respective
bore hole 712 in the elongate tray 110. Alternatively, or in
addition, a mounting assembly also may comprise snap-fit
connectors, such as snap-fit tabs (not shown) each attached to one
of the assembly trays 123 and configured to mate with a respective
notch (not shown) in the elongate tray 110. Alternatively, or in
addition, the mounting assembly also may comprise fitted grooves
(not shown), which may comprise a channel positioned adjacent the
front side 218 of the track member 314 and along a length of each
of the rim members 316 so as to receive each of the assembly trays
123.
[0055] The linear light assembly 100 according to embodiments of
the present invention therefore may provide a very simple and fast
mechanism by which optical assemblies 125 and/or assembly trays 123
(as described above) may be replaced or repaired. For example, and
without limitation, assembly trays 123 may be slid off of or
otherwise removed from the tray 110 in order to replace or repair
the assembly tray 123 and/or the optical assembly 125.
[0056] Referring additionally to FIGS. 8 and 9, the elongate tray
110 may be configured to connect mechanically to a housing 810
and/or a fixture 820. For example, and without limitation, the
linear light assembly 100 may be mounted in an after-market
housing, such as a decorative finish, using a complementary
mechanical connection mechanism that may be present in the housing.
Also for example, and without limitation, the elongate tray 110 may
comprise one or more mounting holes 340 to support attachment of
the linear light assembly 100 to a standard light fixture 820,
and/or may include finish holes 362 to support attachment of a
compatible housing 810 to the linear light assembly 100.
Thermal Communication
[0057] Referring again to FIG. 2, the mechanism by which the
elongate tray 110 may come into thermal communication with each of
the plurality of moveable lighting packages 120 of the light
assembly 100 according to an embodiment of the present invention is
now discussed in greater detail. A person skilled in the art will
appreciate that any manner of dissipating heat from a moveable
lighting package 120 on the elongate tray 110 may be used.
[0058] Continuing to refer to FIG. 2, and referring additionally to
FIGS. 4 and 5, the elongate tray 110 may act as a heat sink that
may dissipate thermal energy generated by the moveable lighting
packages 120 to advantageously improve the performance and increase
the lifespan of the linear light assembly 100. More specifically,
each assembly tray 123 may be mounted on an elongate tray 110 that
may be formed of a thermally conductive material. Heat generated by
one or more light sources 444 within the optical assembly 125 may
therefore be conducted, or passed, to the elongate tray 110.
[0059] *For example, and without limitation, the medial channel
portion 212 may be positioned adjacent the LED package 120 and may
be thermally coupled to the light source 444. This thermal coupling
may be accomplished by any method, including thermal adhesives,
thermal pastes, thermal greases, thermal pads, and all other
methods known in the art. Where a thermal adhesive, paste, or
grease is used, the medial channel portion 212 may be connected to
any part of the moveable lighting package 120 as may effectively
cause thermal transfer between the light source 444 and the
elongate tray 110. Connection point location largely may depend on
the heat distribution within the light source 444. For example, the
medial channel portion 212 may be thermally coupled to one or more
LEDs 444, to the circuit board (not shown), or to both so as to
increase the thermal dissipation capacity of the lighting device
100. The method of thermal coupling may be selected based on
criteria including ease of application/installation, thermal
conductivity, chemical stability, structural stability, and
constraints placed by the linear light assembly 100.
[0060] Continuing to refer to FIGS. 4 and 5, the first and second
flange portions 222 may each present two opposing fin members 426
which, as understood in the field of heat sinks, may be used to
dissipate heat generated by operation of the light source 444. The
fin members 426 may provide a larger surface area that may
otherwise be provided by the surface of the assembly tray 123 and
medial channel portion 212 through which heat may be readily
dissipated. Employment of multiple fin members 426 may increase the
surface area of the elongate tray 110 and may permit thermal fluid
flow between adjacent fin members 426, thereby enhancing the
cooling capability of the elongate tray 110. Additionally, multiple
fin members 426 may be identical in shape. Those skilled in the art
will readily appreciate, however, that the fin members 426 of the
elongate tray 110 may be configured in any way while still
accomplishing the many goals, features and advantages according to
the present invention.
[0061] The configuration of the fin members 426 may be as described
above, or according to the direction of the incorporated
references. In the embodiment of the invention illustrated in FIGS.
4 and 5, the fin members 426 may be configured to extend
substantially the length of the elongate tray 110 (i.e.,
longitudinally coextensive with the track member 314) and to
project perpendicularly outward from the base member 424 in a
generally parallel direction with respect to the main body of the
track member 314. Those skilled in the art will appreciate,
however, that the present invention contemplates the use of fin
members 426 that extend any distance, and that the disclosed
elongate tray 110 that includes fin members 426 that extend
substantially the length thereof is not meant to be limiting in any
way. Those skilled in the art will also appreciate that use of the
term "substantially" with respect to the fin members is meant to
indicate that the fin members 426 of the elongate tray 110 may
extend a length that is equal to the length of the elongate tray or
slightly less than the length of the elongate tray. For the sake of
clarity, fin members 426 that extend a length slightly less than
the elongate tray 110 are meant to include fin members that have a
length anywhere between 50% of the length of the elongate tray to
99% of the length of the elongate tray.
[0062] The medial channel portion 212 and the first and second
flange portions 222 of the elongate tray 110 may be made by
molding, casting, or stamping of a thermally conductive material.
Materials may include, without limitation, thermoplastic, ceramics,
porcelain, aluminum, aluminum alloys, metals, metal alloys, carbon
allotropes, and composite materials. Additional information
directed to the use of heat sinks for dissipating heat in an
illumination apparatus is found in U.S. Pat. No. 7,922,356 titled
Illumination Apparatus for Conducting and Dissipating Heat from a
Light Source, and U.S. Pat. No. 7,824,075 titled Method and
Apparatus for Cooling a Light Bulb, the entire contents of each of
which are incorporated herein by reference.
[0063] The elongate tray 110 may be characterized by a heat
dissipation rate that equals or exceeds a combined heat generation
rate of the plurality of moveable lighting packages 120. Referring
again to FIG. 6, the elongate tray 110 may comprise a plurality of
tray segments 610 each in thermal communication with a subset of
the plurality of moveable lighting packages 120. Each of the tray
segments 610 may have a heat dissipation rate of not less than a
combined heat generation rate of the subset of the moveable
lighting packages 120 with which the tray segment 610 may make
contact. The elongate tray 110 may be constructed of a
heat-dissipating material such as thermoplastic, ceramic,
porcelain, aluminum, and aluminum alloys.
[0064] Alternatively, or in addition, the elongate tray 110 may be
configured to connect thermally to a housing 810 and/or a fixture
820 as illustrated in FIGS. 8 and 9. Such a configuration may cause
the total available heat sink surface area to increase and, as a
consequence, the heat-dissipation capacity of the combined elongate
tray 110 and housing/fixture combination to increase. More
specifically, a combined heat dissipation rate of the elongate tray
110 and of the housing 810 and/or fixture 820 may equal or exceed a
combined heat generation rate of the plurality of moveable lighting
packages 120.
Manufacturing and Installation
[0065] Referring now to flow chart 1000 of FIG. 10, a method aspect
for manufacturing a configurable linear light assembly 100
according to one embodiment of the present invention is discussed
in detail. From the start 1005, the method may include the step of
calculating a potential amount of heat generated by simultaneous
operation of the plurality of moveable lighting packages 120
planned for inclusion in the linear light assembly 100 as designed
(Block 1010). At Block 1020, the elongate tray 110 may be sized by
calculating a potential amount of heat that may be dissipated by
the planned surface area on the elongate tray 110 as designed.
Next, the elongate tray 110 may be molded to a form having a
surface area characterized by a heat dissipation rate of not less
than the combined heat generation rate of the moveable lighting
packages 120 planned for the design (Block 1030). The method may
include attaching a plurality of optical assemblies 123 to a
plurality of assembly trays 125 to create the moveable lighting
packages 120 (Block 1040). For example, and without limitation,
this step may include attaching the optic 442 in a position such
that the optic 442 is in optical communication with the LEDs 444
which, in turn, may be in thermal and mechanical communication with
a circuit board. The assembly tray 125 of each moveable lighting
package 120 may be positioned in thermal and mechanical
communication with the elongate tray 110 at Block 1050. If, at
Block 1055, it is determined the manufactured product 100 is to
include a power supply 230, then light sources 444 in the moveable
lighting packages 120 may be positioned in electrical communication
with the power supply 230 attached to the elongate tray 110 (Block
1060) before the product 100 is shipped to a consumer for
installation at Block 1070. After product shipping, the process
ends 1075.
[0066] Referring now to flow chart 1070 of FIG. 11, a method aspect
for installing a configurable linear light assembly 100 according
to one embodiment of the present invention is discussed in detail.
From the start 1105, the method may include the step of determining
whether the linear light assembly 100 as designed must be
reconfigured for a particular application (Block 1115). For
example, and without limitation, reconfiguration may include
shortening the elongate tray 110 of the assembly 100 to fit a
preexisting fixture or mounting space. If the assembly 100 is to be
reconfigured, then at Block 1120 the moveable lighting packages 120
that may have come preinstalled with the product as shipped may be
removed from the elongate tray 110 to be modified. Similarly, if at
Block 1125 a preinstalled power supply 230 is determined to be
present, then the power supply 230 may be detached from the
elongate tray 110 (Block 1130) in preparation for reconfiguration.
Next, the elongate tray 110 may be reconfigured as desired at Block
1140. For example, and without limitation, the elongate tray 110
may be separated (e.g., by cutting) into a plurality of tray
segments 610. At Block 1150, a subset of moveable lighting packages
120 and the tray segment 610 desired for reassembly may be
identified. If at Block 1155, it is determined that a
manufacturer-supplied power supply 230 is to be reused for the
installation, then the power supply 230 may be repositioned (Block
1160) and mounted (Block 1170) on the desired tray segment 610.
[0067] Still referring to FIG. 11, whether or not the elongate tray
110 is reconfigured after Block 1115, the position of the moveable
lighting packages 120 may be adjusted on the elongate tray 110
(Block 1175). Adjusting the moveable lighting packages 120 may
include moveably positioning each of the moveable lighting packages
120 on the medial channel portion 212 of the desired (remaining)
tray segment(s) 610 (Block 1180), and affixing each of the desired
moveable lighting packages 120 to a respective mounting assembly on
the elongate tray 110 (Block 1185). For example, and without
limitation, additional moveable lighting packages 120 may be
provided by an OEM and attached to the elongate tray 110 in an
after-market reconfiguration.
[0068] At Block 1190, the linear light assembly 100 may be mounted
to a standard light fixture 820, whether or not that assembly 100
may have been shortened (Block 1115) and/or adjusted (Block 1175).
At Block 1195, a determination may be made whether or not to add a
housing 810, such as a finish, external to the linear light
assembly 100. If not, the process ends at Block 1199. Otherwise, a
housing 810 may be mounted to the configurable linear light
assembly 100 (Block 1197) before the process ends at Block
1199.
[0069] Some of the illustrative aspects of the present invention
may be advantageous in solving the problems herein described and
other problems not discussed which are discoverable by a skilled
artisan. While the above description contains much specificity,
these should not be construed as limitations on the scope of any
embodiment, but as exemplifications of the presented embodiments
thereof. Many other ramifications and variations are possible
within the teachings of the various embodiments. While the
invention has been described with reference to exemplary
embodiments, it will be understood by those skilled in the art that
various changes may be made and equivalents may be substituted for
elements thereof without departing from the scope of the invention.
In addition, many modifications may be made to adapt a particular
situation or material to the teachings of the invention without
departing from the essential scope thereof. Therefore, it is
intended that the invention not be limited to the particular
embodiment disclosed as the best or only mode contemplated for
carrying out this invention, but that the invention will include
all embodiments falling within the scope of the appended claims.
Also, in the drawings and the description, there have been
disclosed exemplary embodiments of the invention and, although
specific terms may have been employed, they are unless otherwise
stated used in a generic and descriptive sense only and not for
purposes of limitation, the scope of the invention therefore not
being so limited. Moreover, the use of the terms first, second,
etc. do not denote any order or importance, but rather the terms
first, second, etc. are used to distinguish one element from
another. Furthermore, the use of the terms a, an, etc. do not
denote a limitation of quantity, but rather denote the presence of
at least one of the referenced item.
[0070] Many modifications and other embodiments of the invention
will come to the mind of one skilled in the art having the benefit
of the teachings presented in the foregoing descriptions and the
associated drawings. The scope of the invention should be
determined by the appended claims and their legal equivalents, and
not by the examples given. Therefore, it is understood that the
invention is not to be limited to the specific embodiments
disclosed.
* * * * *